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SERVICE MANUAL Model EC13V 1193S122 ROBIN AMERICA, INC. ROBIN TO WISCONSIN ROBIN ENGINE MODEL CROSS REFERENCE LIST WISCONSIN ROBIN ROBIN 0 SIDE VALVE W 1-080 W1-145 W1-145V W1-185 W1-185V W1-230 W 1-280 W 1-340 W 1-390 Wl-45OV EY21W EY44W EY18-3W EY25W EY27W EY08 EY15 EY 15V EY20 EY2OV EY23 EY28 EY3 5 EY40 EY45V EY2 1 EY44 EY 18-3 EY25 EY27 OVERHEAD VALVE WO1-115 wo1-120 WO1-150 WO1-170 wo1-210 WOl-250 WO 1-300 WO1-300V WO1-340 WO 1-340V WO 1-43 OV EH11 EH12 EH15 EH17 EH21 EH25 EH30 EH30V EH34 EH34V EH43V 0 TWO CYCLE WT1-125V EC13V DIESEL DY23 DY27 DY30 DY35 DY4 1 WRD 1-230 WRD 1-270 -1-300 WRD1-350 WRD1-410 0 FOREWORD I This manual covers the construction, function and sevicing procedures of the Robin engine model EC13V. Good operation and a planned maintenance program as outlined in this manual are of vital importance in obtaining maximum engine performance, and long enginelife. Careful observance of the instructions will result in better, saferservice work, IMPORTANT: All information,illustrations,directionsand.specificationsinthis book are on the basis of information available at the timeit was written. Fuji Heavy Industries Ltd. reserves the right to make changes without incurring any obligation whatever. No part of this publication may be reproduced without written permission. Recoil Starter \ Fuel Tank Lever Carburetor I: P.T.O. Shaft Section Page Title 1. SPECIFICATIONS ........................................... 2 . PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1 Maximum Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2 Continuous Rated Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 2 2 Fuel Consumption Ratio a t ContinuousRated Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . 2.3 Maximum Torque and 3. FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . SECTIONALVIEW of ENGIN€ 3 ............................... 5. DISASSEMBLY and REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 PreparationsandSuggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................... 5 - 3 DisassemblyandReassemblyProcedures 4 6 6 7 8 6. MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6 - 1 Operation of the Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6 - 2 Ignition SystemCheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 6-3 IgnitionUnit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 7. GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 19 GovernorAdjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 7 -2 7-3 8. BREAK IN OPERATION of REASSEMBLED ENGINE 9 . . . . . . . . . . . . . 22 ..................................... StartingDifficulties . . . . . . . : . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slow-speed out of order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OverheatingandKnockjng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLE SHOOTING 23 9-1 9-2 9-3 9-4 9-5 9-6 9-7 23 24 24 24 24 PowerDrop .......................................... ExcessiveFuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Hunting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OtherComplaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. CHECKS and CORRECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12. 20 25 25 26 11 CLEARANCE DATA and LIMITS/TORQUE SPECIFICATIONS . . . . . . 27 MAINTENANCE and STORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 1 Daily ChecksandMaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Every 50 Hours (10 days) Checks and Maintenance . . . . . . . . . . . . 12-3 Every 100 200 Hours (Monthly) Checks and Maintenance . . . . . 12-4 Every 500 600 Hours (Semiannual) Checks and Maintenance . . . 12-5 Every 1000 Hours (Yearly) Checks and Maintenance . . . . . . . . . . . 12-6 Preparation for Long Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - - 29 29 29 29 29 30 30 1 SPECIFICATIONS EC13V Model Type Air-cooled, 2-Cycle, Vertical Shaft, Single Cylinder Gasoline Engine . 56 mm x 50 mm.(2.20 in x 1.97 in) Bore x Stroke . , Piston Displacement 123 cc (7.49 cu. in) Continuous Rated Output 3.2 HP/3600 rpm (2.4 KW/3600 min" ) Max. Output 4.2 HP/4000 rpm (3.1 KW/4000 min" ) Max. Torque 0.8 kg-m/3000 rpm Counter-clockwisefacing to P.T.O. shaft Rotation Forced Air Cooling Cooling System Gasoline Oil Mixing Type (Mixing Ratio50 : 1) Lubrication Lubricant 2-Cycle EngineOil Carburetor Horizontal Draft, Float Type Automobile Gasoline (mixed with oil) Fuel Fuel Consumption Ratio (gr/HP-h) 1 360 a t continuous rated output operation I Gravity Type Fuel Feed Approx. 2.0 liter (0.53 U.S. gal.) Fuel Tank Capacity I Speed Governor Ignition System . Centrifugal Flyweight Type Flywheel Magneto Type (Solid State Igntion) NGK BMGA or CHAMPION CJ8 Spark Plug Recoil Starter Starting System Dry Weight 11.2 kg (24.7 Ibs) 400 mm (15.7 in) Length Dimensions Width 334 mm (13.1 in) 331 mm (13.0 in) Height -1- I 2. PERFORMANCE r\ \ 2-1 MAXIMUMOUTPUT The maximum output of the engine is the power delivered by the engine running with full throttle opening after theengine is throughly broken in. A brand new engine may not produce this maximum output until it has been sufficiently broken in. 2-2 CONTINUOUS RATED OUTPUT The continuous rated outputof the engine is the power delivered by the engine running atan optimum speed most favorable for engine life and fuel consumption. When designing an equipment driven by an engine, it is most important to keep the power requirement less than continuous rated output of the engine. 2-3 MAXIMUM TORQUE.and FUEL CONSUMPTION RATIO AT CONTINUOUS RATED OUTPUT The maximum torque curve of the engine is the output torquecurve at P.T.O. shaft when the engine is running with full throttle opening. Fuel consumption ratio at continuous rated output is the one while the engine is delivering continuous rated output. PERFORMANCE CURVE kg-m HP " 2400 3200 2800 3600 Revolution ____) r.p.m. -2- 4000 0 3. FEATURES " 1. CRANKSHAFT: Forged steel crankshaft assembled with induction hardened crankpin, precision balanced for low engine vibration, durability, greater shock loading resistance and longer life. 2. BEARINGS: Ball bearings at both ends of crankshaft and needle roller bearings a t small end and large end of connecting rod give less friction, better radial support, maximum side loading capability and longer life. 3. ALUMINUM 'CYLINDERand CRANKCASE:Aluminumdie-cast cylinderwith molded-incastiron liner makes the engine light in weight with extra strength, durability, loweroil consumption and longer life. 4. AIR CLEANER: Rugged dual stage. air cleaner with high efficiency, ease of service and longer engine life. 5 . SOLID STATE IGNITION: Solid state, high energy electronic ignition gives more precise ignition timing, hotter spark for easy starting, no breaker points to service, ease of maintenance and longer spark plug life. 6. ALL-SPEED GOVERNOR: Rapid response mechanical flyweight type governor system is fullylubricated with oil mixed .fuel for long life and which enables more precision speed regulation and better reliability. . This all-speed governor system enables the setting for any desired speed by simply moving the control lever. 7. CARBURETOR: Precision modern design withbutterflythrottleandchoke.Removable float type design gives maximum fuel economy and ease of starting. fixed jetand 8. PISTON: High strength aluminum alloy piston--isspecially designed for durability and longer life. 9. PISTON RINGS: Two ring design. Chrominum plated top ring and perkarized second ring give smooth running and durability. 10. FUEL TANK: Large, no rust'resin tank gives.trouble-free long operation. -3- 4. SECTIONAL VIEW of ENGINE Flywheel / \ P.T.O. Shaft -4- Recoil Starter Connecting Rod \ -5- 5. DISASSEMBLY and REASSEMBLY 5-1 PREPARATIONS and SUGGESTIONS 5-1 - 1 DISASSEMBLY When disassembling the engine, memorize where and how each part is assembled in order to reassemble it correctly. Tag parts if there i s a possibility of confusion. Take care not todamage packings and gaskets, whichare fragile. In order toprevent missing and misplacing, group related parts together, tentatively assembling them, immediately after disassembled each sub-assembly. Handle the disassembled parts carefully, andwash them in kerosene. Use the correct toolsin the correct way. Standard tools required for disassembly and reassembly: . a) Work table b) Washing pan c) Disassembling tools . . .. d) Washing oil (kerosene or gasoline), Mobile oil, Brush e> Emery paper, Cloth Before starting to disassemble the engine, drain fuel. (To prevent from danger and stain) 5 - 1 - 2 CLEANING before reassembly 1) Check all sliding and rotating parts, such as piston, cylinder, crankshaft and bearings for defect. 2) Wash the disassembled parts in kerosene to remove dust,dirtandcontaminated oil thoroughly. Wash them twice, first time remove visible dirt roughly, and second timeusing fresh kerosene. 3) After washing, blow them thoroughly with compressed air. 4) Do not wash electric parts. Wipe them with clean cloth and dry them. 5 ) Accumulated carbon on the cylinder head, gasket, piston, cylinder and inside the muffler to be careflly removed, and finish the piston withoil stone to get smooth surface. 6) Parts of carburetor to be washed carefully with gasoline and blow them thoroughly with compressed air. 7) Check the cable for any damage. 8) Air cleaner element shall be washed in the.detergent and dry thoroughly. Then put it to mixture of2 4 kerosene and 1 engine oil, and assemble it after squeezed well. 9) Take special care not to contaminate the parts with dust and applymobile oil on the surface in order to prevent from &st. - 5 - 1-3 CHECKS and CORRECTIONS before reassembly After disassembling and cleaning the engine parts, check them and, if necessary, correct them according the section "11. CLEARANCE DATA and LIMITS/TORQUE SPECIFICATIONS." Gaskets and rubber pipesshall be replaced with new ones, -6- to , n '~, i 0 5-1 - 4 REASSEMBLY 1) Before reassembly, wash parts in kerosene and blow them with compressed air. 2) Apply mobile oil on the rotating and sliding surface. 3) Take care not ‘to contaminate the parts with dust during reassembly. 4) Be sure t o assemble those parts.provided with alignment marks by bringing the marks in alignment. 5 ) Tighten bolts, nuts and screws to the correct torque specified. When there is no torque specification, 6) 7) 8) 9) tighten them to torque readings appropriate to the size. Standard Tightening Torquefor screws are as follows: 6 mm . . . . . . . . . . . . . 90 kg-cm (6.5 ft-lbs) 8 mm . . . . . . . . . . . . . . 250 kg-cm (1 8 ft-lbs) 10 mm . . . . . . . . . . . . . 370 kg-cm (26.7 ft-lbs) If small screws are tightened too hard, they may get broken. Tighten the large size nuts such as ones for the magneto flywheel, enough by giving hammer blows on the socket wrench handle. When tightening the several screws fastening the single part, tighten them all evenly, by alternately tightening diagonally located pairs. Do not applyoil to the part towhich packings or sealing agent t o be applied. When engine is completely reassembled, make sure that thereis no parts remained. During the assembly, turn themoving part by hand to check for friction and noise. After the completion of reassembly, turn the engine by hand, and check if there is any disorder or loose members. 5 - 2 SPECIAL TOOLS Part No. Tool Use Applicable Model 2099500407 Flywheel Puller (without bolt). For pulling off Flywheel All Robin gasoline engines -7- Shape 5-3 DISASSEMBLY and REASSEMBLY PROCEDURE 5 - 3 - 1 FUEL TANK and FUEL TANK BRACKET 1) Disconnect fuel pipe from carburetor. 2) Remove mounting bolts, and detach fuel tank and fuel tank bracket from crankcase and blower housing. CAUTION: Repface fuel pipe once a year in order to prevent from the danger of fuel leakage caused by the cracks. n Tank Band Fuel Tank Bracket I Fuel Pipe Fig. 1 -8- 0 5-3-2 A I R CLEANER 1) Remove air cleaner cover and element. 2) Unscrew two nuts and bolts which clamped air cleaner base plate to carburetor and remove base plate. In reassembly, wash element based on the following procedure before reassembly: 1) Wash outer and inner elements with detergent and dry them thoroughly. 2) Soak them in the mixture of 2 4 kerosene and 1 engine oil, and squeeze the outer element to remove excess oil. - 5-3-3 CARBURETOR 1) Remove governor rod and rod spring from carburetor. 2) Removecarburetorfromcylinderblock. ’ . . In reassembly: Refer to section “7. GOVERNOR.” 5-3-4GOVERNOR LEVER 1 1) Remove governor lever from governor shaft. 2) Remove governor spring from control lever. In reassembly: Refer to section “7. GOVERNOR.”.Assembly shall be made correctly including engine speed adjustment. Screw Cleaner Element Fig. 2 -9- \ Cleaner Cover 5-3-5 MUFFLER Unscrew nuts and remove it from cylinder. 5-3-6 BLOWER HOUSING Unscrew bolts and remove blower housing from crankcase and cylinder head. , 5-3-7 RECOILSTARTER 1) Remove recoil starter from blowerhousing by unscrew 4 x M6 bolts. 2) Remove starting pulley from flywheel by loosing bolts clamped. NOTE: Unless it is necessary, do not disassemble recoil starter as special tools are required for reassembly., Muffler Bolt Recoil Starter Nut ”-% Starting Pulley Bolt Cylinder Baffle Fig. 3 - 10- 5-3-8 MAGNETO and FLYWHEEL (Fig. 4) 1) Remove flywheel from crankshaft. Apply a socket wrenchover the nut at the endof crankshaft and give the wrench handle a sharp blow with a hammer. Remove nut and spring washer. Attach flywheel puller. to. flywheel as illustrated in Fig. 4, turn the center bolt clockwise until flywheel comes loose enough t o be removed. 2) Remove spark plug cap from high tension cable of ignition coil. Then, remove ignition coil from crankcase. In reassembly: Refer t o section “6. MAGNETO.” Ignition Coil =u Flywheel Puller Fig. 4 Bolt Flywheel / I Spark Plu’g Cap Fig. 5 - 11 - Crankshaft 5 - 3 - 9 CYLINDER HEAD 1) Remove spark plug from cylinder head. 2) Unscrew four head bolts and remove cylinder head from cylinder. 3) Remove cylinder head gasket from cylinder. In reassembly: 1) Clean carbon from combustion chamber and dirt from between the cooling fins of cylinder head. Check its mounting face for distortion. 2) Use new cylinder head gasket. NOTE: Cylinder head gasket must be placed folded edge upside (To the cylinderhead). -- 3) Cylinder head fin must be placed in parallel with crankshaft. Tightening torque for head bolt is 180 7 220 kg-cm ( 13 16 ft-lbs). 4) Tightening torque for spark-plugis 250 300 kg-cm (1 8 22 ft-lbs) for a new spark plug. - 5-3-10 CYLINDER 1) Remove cylinder from crankcase by removing nut, springwasher and washer. 2) Remove cylinder gasket. In reassembly: Clean carbon deposit from cylinder head and combustion chamber. CAUTION: Without cleaning the carbon deposit, i t may damage the pistonand inner surface of cylinder when reassembling. ylinder Replace a new one. Intake of cylinder should be positionedto the left againstview from blower side. Applyoil to piston ring and cylinder walls. After assembling the cylinder securely, make sureif the crankshaft rotates smoothly. Tightening torque for cylinder is 180 220 kg-cm (1 3 16 ft-lbs). - - CAUTIONS: 1 ) When fastening cylinder, tighten four nuts evenly. 2) Before reassembling cylinder, apply oil to needle bearing located at the small end of connecting rod. 5-3-1 1 PISTON 1) Remove piston pin clips of both sides. 2 ) Pull piston pin out of the piston, and remove the needle bearing from the small end of connecting rod. CAUTION: In order not to damage piston, hold the piston firmly and pull out piston pin. Also due caution should be exercised when disassembling needle bearing. 3) Remove piston rings from piston, expanding the open ends of therings. - 12- n Washer Spring Washer Nut Fig. 6 - 13- In reassembly: .PISTON RINGS (Fig. 7 and 8 ) If an expander is unavailable, install the ring by placing the open ends of thering on first land of piston, then spread the ring only far enough to slip over the piston and carry it into the correct groove. CA U T I 0NS: I ) Be extremely careful not to distortand break the ring. 2) Put the open ends o f piston rings to the knock pins in thegrooves. (This is to prevent the rings from rotation while operating the engine.) 3) Assemble the rings in the order of the 2nd ringand then top ring. (Fig. 8) Top ring ..................... Chromium plated surface (looks white silver in colour) 2nd ring ...................... Perkarized surface (looks dark in colour) Top Ring Second Ring Fig. 8 Fig. 7 .PISTON 1 ) Position the “F” mark of piston top to flywheel side and reassemble the piston and connecting rod with the needle bearing by gently striking the piston pin. CAUTION: Apply oil to the needle bearing before reassembling it to piston pin. 2) Assemble piston pin clip. CAUTION: Replace piston pin clip if there is any looseness after reassembling it. 3) Be sure that piston and connecting rod move smoothly after reassembled. - 14 - r”\ \ ’ 5 - 3 - 1 2 CRANKCASE Unscrew 5 bolts which fasten upper and lower parts of the crankcase, and divide the crankcase into two parts by tapping with soft hammer, and detach crankshaft connecting rod assy. In reassmbly: 1) Before reassembling upper and 'lower parts of the crankcase, check bearing and oil seals if there is any damage, and in case of any damage being found, replace them with new ones. 2) Apply oil to the bearings of crankcase and ascertain that there is n o warp on the lip of oil seal. Tightening torque is 90 100 kg-cm (6.5 7.0 ft-lbs). Clean the joint of both crankcases and apply sealing agent to the fitting surfaces of bothcrankcases. Assemble the crankshaft and join both crankcases withpress (or tap them with a soft hammer)having extra care not to damage the oil seal. CAUTION: When reassembling the crankcase, tighten the diagonally located pairs of bolts according to - - the specified tightening torque. NOTE: After reassembling the crankshaft to the crankcase, check if the crankshaft rotates smoothly, 5-3-13 CRANKSHAFT and CONNECTING ROD ASSY Do not take apart the crankshaftand connecting rod. Crankshaft and connecting rod assembly is supplied as a spare part. Crankshaft - 15- 5-3-14GOVERNOR’PLATE ’ Pull out governor plate, governorsleeve from crankshaft. In reassembly: Reassembly is just reverse of disassembly sequence. 5 - 3 - 1 5 GOVERNORSHAFT 1) Unscrew 2 screws and remove governor yoke. 2) Pull out governor shaft from crankcase. NOTE: Do not disassemble unless it is required. In reassembly: Refer t o section “7. GOVERNOR.” 5-3-16CONTROLLEVER Unless it is required, do not remove control lever from crankcase. For disassembly and reassembly procedures, refer to section “7. GOVERNOR.” Flange Bolt Choke Rod . Choke Lever Governor Yoke I’ Governor Plate Governor Shaft Fig. 10 - 16- a 6. MAGNETO - EC13V engine is equipped with a pointless Solid State Ignition system. Thisis a circuit breaker type ignition device which utilizes the power transist,oras an element for controlling electric current. This system is free from start-up failure due to dirty, burntor oxidized point surfaces, low ignition efficiency because of moisture, rough' breaker point surface and incorrect timingresulting from worn mechanical parts. 6-1 OPERATION of the IGNITION SYSTEM This system is referred to as T.C.I. (Transistor Controlled Ignition) system. As illustrated in Fig. 1 1, this is a simple system, consisting of a flywheel with magnetic fields,an ignition coil with built-in transistor, and lead wires to spark plug and stop switch. Rotation of the flywheel generates a voltage on the primary side of the ignition coil. By this voltage, electric current (11 ) flows through the resistor (RI) to thebase of the power transistor. This current actuates the transistor to permits the amplified flow of current (IC). With further rotation of the flywheel, the voltage at the point @ reaches up to thetrigger voltage of the thyrister (SCR) and the current ( 1 3 ) flows eliminating current (11). At this moment, current (IC)is cut off abruptly resulting in high voltage on the secondary side of the ignition coil, which in turn fires the spark plug. RESISTOR Fig. 12 . * IGNITION COIL WITH BUILT-IN TRANSISTOR BLACK a 0 Fig. 1 1 WIRINGDIAGRAM SOLID STATE IGNITION IGNITION COIL T.C. IGNITION CIRCUIT - 17 - 6-2 IGNITION SYSTEM CHECK In the event of malfunction of the ignition system, check the followings at first: 0 Broken, frayed, loose or disconnected ignition wires. 0 Faulty spark plug-wet, dirty, insulation broken or incorrect plug gap. ' If difficulty is experienced in starting the engine or if engine misses firing, the strength of the ignition spark should be checked: Remove spark plug-then with the ignition cable connected to it, lay the spark plug on a convenient metal part of the engine so that the gap can be observed as you rotate the crankshaftseveral times by means of the recoil starter. If a good strong spark occurs, the ignition system can be eliminated as the source of trouble. If there is a weak spark or no spark at all, check the ignition system as follows': 1) Check to make sure that the external magnet, mounted on the flywheel is in a good condition. 2) Since the solid state ignition unit is self-contained, the only testing which can be performed is on the secondary coil resistance. Using a good quality ohm-meter, check the secondary coil resistance between the plug terminal of the ignition cord and the coreof the ignition coil. This resistance reading should be approximately 13,000 ohms f 10%.If the resistance reading is infinite, this indicates open winding in the ignition unit, a loose or broken spark plug connector or a failed high tension lead. If a very low reading is taken, the secondary coil is probably shorted. If, after testing, the ignition unit itself is determined to be faulty, then itwill have to bereplaced. n 6-3 IGNITION UNIT INSTALLATION '\.. When installing the ignition unit on the crankcase, use a non-metallic feeler gauge to measure the airgap between the ignition coil and flywheel. The ignition coil can be moved t o adjust the air-gap by loosening its holddownscrews. Adjust the air-gap between 0.4 0.5 mm (0.0 16" - - 0.02"). Fig. 13 NOTE: I f the flywheel is removed, wipe off oil and grease thoroughly from the tapered portion of the crankshaft and flywheel before reassembly. Tightening Torque for flywheel nut 390 I - 420 kg-cm (28 - 30 ft-lbs) - 18 - J 7. GOVERNOR 7 - 1 CONSTRUCTION and OPERATION A centrifugal flyweight type governor is used. The governor plate, governorsleeve and governor yoke are installed in the crankcase, and lubricated by the oil mixed -fuel. As the enginespeedfluctuates,flyweightsonthegovernorplate,rotatingtogetherwith the crankshaft, changes its opening angle and moves the governor sleeve, which in turn rotates the governor shaft through the governor yoke. The governor lever is connected to the extending part of the governor shaft and this governor lever is connected to the carburetor throttle lever through the governor rod at the other end; thus the throttlevalve is opened or closed and engine speed andoutput are controlled. When the crankshaft speed increases, all the relevant members move in the direction indicated by marks and the carburetor throttle valve closes, reducing the fuel supply and consequently reducing the speed and output. When the crankshaft speed decreases, the same members move in the direction indicated by -e marks and the carburetor throttlevalve open, increasing the fuel supply and consequently recovering the failing speed and output. +a- Throttle Valve Choke Valve Fig. 14 - 19- 7-2 GOVERNORADJUSTMENT The governor system should adjusted be reassembly at f-7 by the following procedures. \ 1) Connect governor rod and rodspring to carburetor throttlelever and governor lever, then install governor lever t o governor shaft. NOTE: Never tighten the set screw for the adjusting plate at this time, and do not fix adjusting plate, governor leverand governor shaft. 2) Connect governor lever and control lever with governor spring, and install control lever to crankcase. And the governor adjustmentis t o be made in the following sequence: a)Attachthe governor lever onthegovernor shaft. b) To the governor shaft, fasten temporarily the adjusting plate with nut and spring washer. c) To the governorlever, fasten temporarily the adjusting plate with screw and washer assy. At this moment, the adjusting plateis free t o move. (See Fig. 15.) d) Pushdown the adjustingplatedownward and tighten the screw. (See Fig. 16.) e,) Setthespeedcontrol lever at the position “High,” and tighten the nut. (SeeFig. 17.) I Nut Fig. 15 Screw and Washer Assy fl \, Fig. 17 Fig. 16 - 20 - ” 7-3 HIGH SPEED ADJUSTMENT (Fig. 16) 7-3-1 WHEN NO TACHOMETER Is AVAILABLE Unless required in the process of disassembling, do not remove control lever and/or other related parts from crankcase. If it is necessary to remove them, never turn high speed stopper bolt on controllever (Fig. 18). 7-3-2 WHEN A TACHOMETER IS AVAILABLE 1) Install control lever and other related parts. 2) By turriing control lever with governor spring on it, increase gradually the engine speed up to specified engine speed. 3) Locate high speed stopper bolt on the control lever and lock it so that it will work as stopper of control lever against the stopper plate. Make sure that the governor spring is hooked in the same hole on the governor lever as original. There are 5 holes on the governorlever. Normally, hook governor spring in the center hole. Speed Control Lever \ Choke Lever Governor \ Fig. 18 - 21 - 8. BREAK IN OPERATION of REASSEMBLEDENGINE f-l >\ An overhauled engine must be carefully broken in to get proper surface condition on newly installed parts. Especially when cylinder, piston or piston rings are replaced, a thorough break in operation is indispensable, The recommended breakin schedule is as follows: I LOAD " 1 SPEED I NO LOAD 1 2,000 rpm I NO LOAD I 3,000 rpm NO LOAD . I O minutes I I 10 minutes I I 60 minutes I TIME 3,600 rpm , _ 1.6 HP I 1 1 I 3,600rpm I ~~ 3.2 HP 3,600 rpm NOTE: Use 25: I oil mixed fuel for break in period. - 22 - i a 9: TROUBLE SHOOTING For a gasoline engine to start and run satisfactorily, the following three requirements must be met: 1) A proper fuel-air mixture is supplied to the combustion chamber. 2) An appropriate compression in the cylinder. 3) Good spark at correct time to ignite the mixture. If all the three requirements are not met simultaneously, an engine cannot be started. There are also other factors such as heavy load at'starting or too longan exhaust pipe causing a high back pressure, which contribute to hard starting. The most commoncauses of engine troubles aregiven below. 9-1 STARTING DIFFICULTIES Remedy Cause Preventive measure 1) I f contaminated, wash in gasoline, re- 1) Use spark plugs of specified heat range. Defects in spark plug move foreign matters and dry. 2) If spark plug is broken or lost insulation, replace plug. 3) Adjust spark gap to 0.6 0.7 mm. Do not use poor grade.oil.Clean air cleaner and avoid dust entry. 2) DO not hit or bend the center electrode of the spark plug a t adjusting or the insulator may get damaged. Defects in high-tension cord I f cord is burnt or damaged, replace the ignition coil unit. Defects in magneto 1 ) If wire or insulation is broken, replace magneto. 2) If magnetism is weak, re-magnetize ( a t the magneto maker) or replace flywheel. - 1 ) I f switch i s faulty (short circuit), replace or repair. Other defects in electric system 2) If primary wire is grounded to the Gas leak through head gasket or other parts 2) If head bolts are loose, tighten. 3) If spark plug is loose, tighten. . engine body, insulate it with insulating tape. 1 ) If headgasket is defective, replace. 4) I f spark plug is defective, replace. 1) If piston is worn, replace. 2) If cylinder is worn, re-bore and use over. Defects in piston assembly 1 ) Keep air cleaner always clean. 2) Do not use poor grade oil. size piston and piston ring. 3) I f piston rings are worn, replace. 4) If piston rings are stuck, clean or replace rings. Defects in fuel tank system Defects in carburetor 1) Clean clogged tank outlet. 2) Cleanclogged fuel strainer. 3) I f incorrect fuel is poured into tank or water is mixed, drain tank completely and fill it with correct fuel. 4) When fuel pipe is locked with air, discharge air. 1 ) If clogged with dust, clean. 2) If defective,replace. Clean j e t s and other orifices, if they are clogged. - 23 - 1 ) Be sure t o use a filter when adding fuel. 2) Use mixture (gasoline 50 : 1 ) as fuel. Cause Defects in carburetor Excess load 1 ) Start engine with fully open choke valve and half open throttle valve. 1) Never close choke valve when engine is 2) Remove drain plug from crankcase, and 2) When stopping the engine, run it a t slow close fuel cock, repeat starting operation several times t o discharge excess fuel. Defects in fuel supply I Preventive measure Remedy 1 If fueloverflows, checkneedle valve seat for wear. Replace, if necessary. warm. speed for a while. This practicenot only favorably affects next starting,but also improves engine life. 3) Clogged air cleaner results in too rich air fuel mixture. Clean it throughly. Be careful clogged carburetor. 1) If tension of transmission belt is too tight, tension. reduce 2) If load is still too heavy, install a clutch. I r Piston Or Connecting Rod seized 1 ) If piston seizes, repair or replace. 2) If connecting rod large end or small end seize, replace. ~ 1 ) Do not use poor grade oil. 2) Use fuel of proper mixing ratio. . . ~~ ~ ~~ ~~ 9-2 SLOW-SPEED out of order Most defects listed ascauses for starting difficulty arealso causes for faulty slow-speed operating. 9-3 OVERHEATING and KNOCKING 1) If too much carbon deposits are accumulated in the combustion chamber, remove it. 2) If the heat range of the spark plug is too cool, replace it with a correct one, i. e. NGK BM6A or CHAMPION CJ8. 3) If the air-fuel mixture is too lean, clean jets and otherpassages in the carburetor. Clean the air cleaneralso. 4) If the load is in excess, reduce it below the specified continuous load. r\ ~ .I 9-4 POWER DROP 1) If the cylinder, piston or piston rings are worn, replace them or re-bore the cylinder and fit oversize piston and piston rings. Replace or clean piston rings if they are stuck in the grooves. 2) If the carburetor is out of order, re-adjust or clean it. 3) If the spark plugis faulty (contamination, gas leakage or faulty insulation), clean it or replace it. 4) If combustion gas leaks through the head gasket, re-tighten the clamping screws. If the gasket is faulty, replace it. 5) If the magneto is faulty, replace them. 6) If the air cleaner is clogged, clean.it. 7) If the fuel system is clogged, clean it. 8) If the oil seals at the crankshaft are worn and the compressedgas are leaking, replace them. 9-5 EXCESSIVE FUEL CONSUMPTION 1) If air-fuel mixture is too rich, clean jets andpassages in carburetor. 2) Ifthrottle theshaft of carburetor is worn, replace throttle shaft. (carburetor) 3) If fuel is leaking, re-tighten screws or replace faulty part. 4) If the engine suffers power drop accompanied with excessive fuel consumption, trouble-shoot by following step 9-4. - 24 - ‘rj l 1 9-6 ENGINE HUNTING 1) If the governor lever, governor shaft, governor spring or other members are incorrectly adjusted, re-adjust or correct them. 2) If the fuel-air mixture is too lean, clean and adjust the carburetor. 3) If the governor springis distorted permanently, replace it. 4) If the governor sleeve is not functioning correctly, correct it. 5) If the flyweight or the governor sleeve is worn, replace it. 6) If the governor shaft does not move smoothly, correct it. 9-7 OTHER COMPLAINTS 1) Fuel overflows from carburetor. If the fuel flows into the air cleaner or much fuel flows'into the crankcase while the engine is standing still (over-flowing),the needle valve or the floatis fauity. Correct or replace them. ,2) If the engine suddenly stops with abnormal noise, the piston or the crankshaft or the connecting rod is seized. Repair or replace them. 3) If the engine produces abnormal noise during operation, be sure to stop the engine and do not start it again before the cause is removed. If the cause of the trouble cannot be found, contact your dealer and ask them for service. - 25 .- IO. CHECKS and CORRECTIONS After disassembling and cleaning the engine parts, check them, and if necessary, correct them according to the correction table. The correction table applies whenever engines are repaired. Its contents shouldbe thoroughly understood by those who undertake the repairing. Its specifications must be abidedby to effect correct maintenance. Followings are the terms employed in the correction table. CORRECTION All operations performed on the engine parts for the purposeof improving or recovering the engine performance, consisting of repairs, readjustments, and replacements. STANDARD SIZE The design dimension of the part without the tolerance. CORRECTION TOLERANCE The tolerance on there-finished part dimension or on the readjusted dimension. CORRECTION LIMIT changes, due to The limit on the part and adjustment, beyond which any dimensional and functional wear, burn, and othercauses will adversely affect the normal engine performance. USE LIMIT , The limit, beyond which the partis no longer usable, due to defectsin function or strength. NOTE: All dimentions in the "CLEARANCE DATA AND LIMITS/7ORQUE SPECIF1CATIONS"are given in millimeter, except where otherwise specified. - 26 - 11. CLEARANCEDATA and LIMITS/TORQUE SPECIFICATIONS I -LIMIT USE LIMIT REMARKS 0.2 S .T.D . $156 056.25 056.50 O.S. O.S. Bore Roundness 0.1 5 S.T.D. G55.96 0 -0.01 5 0,s. 056.21 O.S. 056.46 Outside Diameter 1 I G12 Top 2nd Clearance between pisto r inn ag nd piston aroove I Clearance between piston and cylinder I Fit between piston and piston pin r- wR i ditnhg Piston pin O.D. I end Large +0.060 2.0 +0.040 1 I I a Large end side or small side end Parallelism and Twist between large end and small end bores -0.1 Correct Cylinder gauge Boring Micrometer Replace Cylinder gauge Replace - 0.74 TOP 2nd TOP 2nd 2.35 @12 @24 0.004 -- 0.09 0.07 I I I I I 0.1 - 0.25 io.1 -0.008 I +:'009 +0.011 0.1 5 Vernier caliper Replace 0.1 5 0.15 Feeler gauge Replace 0.25 0.25 Cylinder gauge. Micrometer Replace 0.06L 0.06 L Cylinder gauge. Micrometer Replace 1.5 1.5 Feelergauge Replace -0.1 Micrometer Replace -0.03 -0.03 Micrometer Replace +0.020 t0.020 +0.055 t0.055 1 Max. cylinder dia. and min. piston dia. Cylinder Clearance in radial direc- I 0.003 - 0.027 0.5 - 0.1 I I I 0.055 0.055 0.7 0.7 0.1 0.1 Cylinder gauge. Micrometer Cylinder gauge +0.020 +0.020 0 I I Twist 0.1 5 - 0 : -0.003 I Parallelism -0.035 tion @16 I I -0.035 +0.020 - 0.022 I - 20.5 +0.040 0.05 0.03 0.04 I.D. between Clearance small end I.D. and piston pin needle bearing J.011 2.0 TOP 2nd I.D. Clearance between r o d large e n d I.D. and crank pin needle bearing end Small , 0.008L-0.008T I 1 I Ring gap -0.1 Diameter f r o m bottom, in traverse t o p i s t o n pin (max. dia.) 3 Width of ring groove e Surface date, Feeler 0.01 5 Cylindricity Piston pin hole CORRECTION METHOD 0.65 0.01 , TOOL Clearance in radial direction Cylinder gauge, Micrometer Replace Obtain correct clearance by replacing parts Replace Obtain correct clearance by replacing parts I 0.08 0.08 0.3 - 27 - 0.3 Holding large e n d as reference, measure test bar, (L = 100) inserted in small and large e n d Feeler gauge Replace Test bar, Dialindicator Replace ITEM ' 1 Large and small end I.D. roundness & cylindricity STANDARD SIZE I TOLERANCE Max. 0.004 Max. 0.004 Roundness Cylindricity Distance between large e n d & s m a l l end bores a Roundness Cylindricity I I I I Crankshaft journal $ J ~ ~ ' TOOL CORRECTION METHOD Replace Micrometer Replace Max. 0.005 Mzx. 0.005 Micrometer Replace +0.003 -0.006 Micrometer Replace Measure between bearing & crankshaft Feeler gauge Replace Supporting assembled crankshaft between centers, measure journal. Dialindicator Correct Micrometer Replace -7" -0.005 Crankpin O.D. Roundness Q.D. t i0.25 Crankpin O.D. 1t I Mandrels, Micrometer t 0.05 -0.020 -0.020 P ' REMARKS I 0 crankshaft between Runout of crankshaft - 0.2 0.05 I o Dia. of small end needle bearing needles -0.004 unscrew Fixed CHAMPION . plug Spark CJ8 NGK BM6A I I rl 18"(fixed) gap .- plug 2 0.6 Spark - +0.1 1.0 0 0) 1 ~~ u1 Min. gap Magnet revolution: 400 r p m 5 Spark ~ Adjust TORQUE SPECIFICATIONS ITEM m Flywheel nut .E 0). 6+ F9 , Spark plug z? z ?L v) . Cylinder nuts Crankcase bolts - 420 250 - 300 - 220 390 90 - 100 REMARKS ft-lbs kg-ern 28 1 - 28 - - 30 - 22 13 - 16 180 6.5 - 7.3 18 TOOL Torque wrench r) \., I head 12. MAINTENANCE and STORING The following maintenance jobs apply when the engine is operated correctly under normal conditions. The indicated maintenance intervals are by no means guarantees for maintenance free operations during these intervals. For example, if the engine is operated in extremely dusty conditions, the air cleaner should-be cleaned every day instead of every 50 hours. 12-1 DAILY CHECKS and MAINTENANCE I Maintenance and Checks I 1 them requiringforReasons Remove dust from whatever parts which accumuThe governor linkage is especially susceptible to dust. lated dust. Check external fuelleakage. If any, retighten the loose part or replace faulty part. Danger of causing fire Check screw tightening. If any loose one is found, re-tighten: Loose screws and nuts will cause vibration reasulting in the engine damage. I 12-2 EVERY 50 HOURS (10 DAYS) CHECK and MAINTENANCE Reasons for requiring them Checks and Maintenance Clean air cleaner Clogged air cleaner affects engine operation. Check spark plug. If contaminated, wash in gasoline or polish with emery paper. Output power is reduced and startingis made difficult. 12-3 EVERY 100 - 200 HOURS (MONTHLY) CHECKS and MAINTENANCE Checks and Maintenance I I I Reasons for requiring them - 600 HOUUS (SEMIANNUAL) CHECKS and MAINTENANCE Maintenance and Checks cylinderRemove deposit. Remove carbon deposit from exhaust port and muffler. - . The carburetor will be clogged with dirt or dust causing bad starting or poor operation. Clean fuel strainer and fuel tank. 12-4 EVERY 500 ' Disassemble and clean carburetor. I forReasons I The engine output power drops. I requiring them The carburetor will be dogged causing bad starting or poor operation. - 29 - I I 12-5 EVERY 1000 HOURS (YEARLY) CHECKS and MAINTENANCE Checks and Maintenance Reasons Perform overhaul, clean, correcfor replace parts. for requiring them The engine output drops andbecomes out of order. Change piston rings. Replace fuel pipe once a year. Rubber pipes may be hardened andcracked by the ozone in the air. I 12-6 PREPARATION for LONG STORAGE 1) Perform the above 12-1 and 12-2 maintenance jobs. 2) Drain fuel from the fuel tank, carburetor float chamber and fuel lines. 3) To prevent rust in the cylinder bore, apply oil through the spark plug hole and turn the crankshaft for several turns by hand. Re-install the spark plug. Turn the starting pulley by hand and leave it where the resistance is the heaviest. 4) Clean the engine outside with oiled cloth. 5) Put a vinyl or other cover over the engine and store the engine in dry place. n ', - 30 - Industrial Engines
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